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Unread 09-11-2014, 12:40 PM   #1
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Question my 48 volt charger and new charger not coming on no

I recently restored my 99 club car 48 volt ds. I installed Rebuilt moto(EMPr, upgraded rebuilt 400 amp controller(CTS), hd solenoid, 2 ga battery/motor cables(thanks Scotty B). The cart itself runs great. Though when i tried plugging the charger in I got nothing. The charger would not turn on.

Before the rebuild the charger worked fine. I did replace the relay in the past. I tried hooking my friends known working 48 volt charger (powerdrive 3 by Lester) and again nothing. I disconnected the 3/8 amp fuse at gray wire going into charger receptacle. I ran a jumper wire from main negative on battery six to the gray wire going into the charger receptacle. Both my charger and second charger would click and amp meter jump a fraction to about 1. After that nothing. I would touch jumper to gray wire repeatedly and would click each time followed by nothing. I would jumper and gray together for 20 seconds and a click followed by nothing.

My battery pack tests at 47.6 and charger receptacle tests at 47.3. Any ideas on why i am unable to get the charger to charge?
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Unread 09-11-2014, 01:01 PM   #2
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Default Re: my 48 volt charger and new charger not coming on no

Welcome to BGW



You said you changed the battery cables to 2 ga what did you do with the ground cable that went through the OBC ?
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Unread 09-11-2014, 02:42 PM   #3
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Default Re: my 48 volt charger and new charger not coming on no

Thank you for the Welcome!


I cut the 6 Ga wire going through the OBC and installed the stud through the OBC that came with my 2 Ga wire kit. The stud is acting in place of the 6 Ga wire.

The stud has two nuts on the front side and 2 nuts on the back side. I installed a 2 Ga wire to the stud on the front side of the OBC and attatched same 2 Ga wire to the negative terminal on battery 6. I attached another 2 Ga wire to the back side of the stud (back side of OBC) and ran that same 2 Ga wire to the controller.
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Unread 09-11-2014, 04:05 PM   #4
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Default Re: my 48 volt charger and new charger not coming on no

47.6 volts probably isn't enough to get the auto charger to come on
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Unread 09-11-2014, 05:08 PM   #5
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Default Re: my 48 volt charger and new charger not coming on no

I will have to drive it around and run them down a little more to see if thats what it could be. I didn't realize it could be something that simple. I assumed being the batteries were below 48 volts the charger would kick on.


Thanks for the input upstate NY.... I too am form upstate NY!
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Unread 09-11-2014, 05:14 PM   #6
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Default Re: my 48 volt charger and new charger not coming on no

No, what I meant is that 47.6 is too low and is not high enough to turn it on

Where in Upstate NY are you from?
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Unread 09-11-2014, 06:53 PM   #7
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Default Re: my 48 volt charger and new charger not coming on no

Oh must be since i started the rebuild a couple of months ago the batteries sat too long without a charge? They are only a couple years old with minimal swelling. I didn't charge them for about 3 months.

How do i charge them up enough to find out if that is whats causing the charger not to kick on?


I am from Binghamton, NY.
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Unread 09-11-2014, 07:01 PM   #8
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Default Re: my 48 volt charger and new charger not coming on no

You can throw them on the 12v automotive charger long enough to get them to around 8 volts or so, then plug in the CC charger and it should kick on
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Unread 09-12-2014, 06:21 AM   #9
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Default Re: my 48 volt charger and new charger not coming on no

Okay I will try that and get back with the results.
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Unread 09-12-2014, 07:57 AM   #10
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Default Re: my 48 volt charger and new charger not coming on no

. . 47.6v pack voltage is high enough for charger to kick on . . . double check your wiring on the batteries and make sure you did not put a battery in backwards . . .
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